The diploma thesis deals with surface integrity evaluation for different types of steels after case hardening and machining. This thesis compares Barkhausen noise analyses with residual stress depth profile set by X-Ray diffraction method with consideration of different penetration depth of both method. General purpouse of this thesis is verify the concept of the Sum Of Effective Residual Stresses as the index of part quality evaluation during manufacturing process.

This thesis deals with simulation of cooling of rail during its passing through cooling device which has been designed by the heat transfer and fluid flow laboratory. Inputs of the computational model have been set up to get best possible correspondence between outputs of the computational model and results of experimental measurement. The solution with using of model of austenitic stainless steel is provided in first part of the thesis. The solution with considering model of carbon steel is performed in next part. Using of model of carbon steel allows including evolution of latent heat during phase changing. A fields of residual stress has been calculated for different cooling conditions in the last part of this thesis.

Tension leveling is a process used in the steel industry in order to eliminate any shape imperfections of cold-rolled thin strips. The master thesis deals with developing a computer program that generates basic parameters of tension leveling line. The theoretical part of the thesis summarizes the types of the shape imperfections in strips, their causes and the principles of their elimination. This part also presents the mechanism of tension leveling and describes the present-day design of tension levelers. The practical part of the thesis starts with an analytical description of stress-strain behaviour of strip during tension leveling (supposing the simplified conditions). A computer program that allows devising basic parameters of tension leveling line is created on the basis of these analytical relations. The program results are successfully verified by numerical model based on the finite element method (FEM) created in the program ANSYS. Then the interdependencies of certain input and output parameters of created program are determined. These interdependencies can be used as effective design of tension leveling lines.

This thesis deals with the influence of changes in cutting parameters and tool geometry on residual stress inside the material. I examine the influence by deep drilling. Changing the cutting parameters concerns the alteration of the tool feed and the pressure of the coolant during the process. The influence of tool geometry is studied by using two different single edge cannon drills. The research was realized in cooperation with Bosch Diesel Ltd. The theoretical part includes a description of the injection system, in which a high-pressure container is contained. The high-pressure container was used to evaluate the influence of the cutting parameters and tool geometry on residual stress. Furthermore, the theoretical part deals with the deep drilling technology used and the theory of residual stresses. The practical part shows the measurement parameters and the corresponding results. In the conclusion of this thesis, a technical-economic evaluation of the measurement is conducted.

<p>This study is focused on the prediction of residual stresses and microstructure development of steel and aluminum alloys during laser-based manufacturing processes by means of multi-physics numerical modeling.</p> <p>A finite element model is developed to predict solid-state phase transformation, material hardness, and residual stresses produced during laser-based manufacturing processes such as laser hardening and laser additive manufacturing processes based on the predicted temperature and geometry from a free-surface tracking laser deposition model. The solid-state phase transformational model considers heating, cooling, and multiple laser track heating and cooling as well as multiple layer tempering effects. The residual stress model is applied to the laser hardening of 4140 steel and to laser direct deposition of H13 tool steel and includes the effects of thermal strain and solid-state phase transformational strain based on the resultant phase distributions. Predicted results, including material hardness and residual stresses, are validated with measured values.</p> <p>Two dendrite growth predictive models are also developed to simulate microsegregation and dendrite growth during laser-based manufacturing processes that involve melting and solidification of multicomponent alloys such as laser welding and laser-based additive manufacturing processes. The first model uses the Phase Field method to predict dendrite growth and microsegregation in 2D and 3D. It is validated against simple 2D and 3D cases of single dendrite growth as well as 2D and 3D cases of multiple dendrite growth. It is then applied to laser welding of aluminum alloy Al 6061 and used to predict microstructure within a small domain. </p> The second model uses a novel technique by combining the Cellular Automata method and the Phase Field method to accurately predict solidification on a larger scale with the intent of modeling dendrite growth. The greater computational efficiency of the this model allows for the simulation of entire weld pools in 2D. The model is validated against an analytical model and results in the literature.

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<p> The automotive industry is using advanced high strength steels (AHSS) to improve the fuel efficiency of passenger vehicles by lightweighting strategy. The higher strength of AHSS allows vehicle manufacturers to implement thinner and lighter components while still meet the safety requirements. Press hardened steels (PHS) exhibit the highest tensile strength among AHSS and are widely used for manufacturing crash relevant automotive parts. Boron-containing steel with enhanced hardenability is the most commonly used grade of steel for press hardening. The addition of a small amount of boron, 0.002 – 0.005 wt.%, can effectively increase hardenability. However, the boron addition also causes problems in commercially production of steel slabs by continuous casting. Defects including transverse corner cracks, surface cracks, and internal halfway cracks are sometimes found in continuously-cast boron steel slabs during or after the final cooling process. These problems can arise during the post-casting cooling process because boron addition changes the phase transformation behavior of steel.</p> <p>The cooling of slabs during and after continuous casting is a multiphysics process including coupled heat transfer, solidification, solid-solid phase transformations, and deformation. Numerical models are helpful for a better understanding of the cooling process and the interaction of different physical phenomena in it. In this work, a 3-D thermomechanical finite volume model (FVM) with coupled heat transfer, stress, and phase transformation calculations is developed to investigate the temperature history, phase evolution, and stress development during cooling.</p> <p>The model is used to simulate the cooling process of continuous cast steel slabs at different post-casting stages. The effect of boron addition on stress development and phase evolution during cooling of a single slab is investigated via simulation of both boron-containing and non-boron steels. The results show the slab with boron consists of mostly bainite, in contrast to the non-boron grade which is mostly ferrite and pearlite after cooling. Higher tensile stresses, both peak and residual, and plastic strains, which could lead to cracking, are observed at the edge of slab in the boron-containing grade. The effect of slowing the cooling rate by using a radiation shield is studied for the boron-containing steel. The reduced thermal gradient and the increased ferrite formation reduce the stresses in the slab. The cooling process of a stack of multiple slabs is also simulated to study the influence of slabs stacking on cooling rate and slab deformation. A slower cooling rate can be achieved in stacked slabs and the compressive load provided by slabs above the slab can prevent large deformation and flatten the slab during cooling. The combination of slab stacking and radiation shield is modeled to study the stress development under a slow cooling rate that is feasible in practice. Boron addition also affects the water quenching process of steel strips on the runout table after hot rolling. Simulations of strips with and without boron show different cooling curves, residual stress and phase distributions as austenite decomposition does not occur for boron-containing steel due to the fast cooling rate. Therefore, the cooling strategy on the runout table should be adjusted accordingly to control the coiling temperature and improve strip quality.</p>

Every day aircraft pilots must successfully resolve significant inflight situations and then manage the possibility of residual psychological and physiological stress. Previous research has shown primary attention is given to presignificant event training and stress management, however there remains an important gap in the current literature regarding postsignificant event stress within the aviation profession. The purpose of this cross-sectional quantitative study was to use the observational lens of stress theory and survey U.S. pilots who have experienced an inflight emergency, looking for correlation between factors such as age, gender, flight experience, and training against a pilot's self-reported level of residual stress. Using snowball sampling methodology, 101 pilots were anonymously surveyed, with 89% responding that they had some level of residual stress via the Impact of Event Scale-Revised instrument. Using multiple linear regression analysis, the correlation between 9 personal and professional characteristics and pilot's stress level was significant, at R2 =.22, adjusted R2=.14, F(9, 91) = 2.8, p < .01. The sample's correlation coefficient was .47, indicating that approximately 22% of the variance in the residual stress was accounted for by the 9 personal and professional characteristics. Findings from this research will help clarify how pilot training and demographics can affect postsignificant event stress. This knowledge will be an important contribution to the existing literature and enhance social initiatives though an increased awareness of residual stress within the pilot profession. The results can be used to increase aviation safety by enabling the industry and government entities to develop and implement effective stress training initiatives.

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